Label package construction

ABSTRACT

Label packages including a backing sheet and inner face paper housing the labels are flimsy and thereby susceptible to damage due to flexing. Several embodiments for sturdy foldable packaging of printable labels are disclosed. The packaging includes a heavy, sturdy backing sheet in one embodiment to preclude the packaging from flexing, thereby damaging the labels. In another embodiment a sturdy insert card is placed in the packaging. In a further embodiment, a sturdy and thick backing card is placed in the packaging. In a still further embodiment see-through windows in the design allow the customer easier viewing access to choose the style of labels based on his/her preference. In another embodiment, the labels and the surrounding matrix are patterned differently for ease in identifying the labels from the matrix for easier peel-off of the labels.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/297,953, which was filed on Jun. 13, 2001 and whose entire contents are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to sheets of printable labels and, in particular, to a self-contained printable label packaging that can be displayed and sold.

[0003] Sheets of blank printable labels are sold in packages, so that the customers can print relevant information on the labels. Typically, in the prior art, each sheet is foldable as shown in FIG. 1, and such as is available from Avery Dennison Corporation of Pasadena, Calif. The outer surface of this sheet has marketing or other information printed on it, and the inner surface has a layer of adhesive for affixing a die-cut face sheet having a predetermined style of labels. These labels can be hand printed, typed or computer printed.

[0004]FIG. 1 depicts a prior art package 1 comprising multiple panels 2 of paper-based sheet material that can be folded along the perforations 8. A series of printable labels 4 reside on an inner face 22. The inner face is releasably affixed by means of adhesive to a backing sheet (not shown). Means for hanging the label package 1 (comprising the sheet and labels) is achieved via an opening 6 in the sheet.

[0005] The outer face of the foldable sheet of FIG. 1 is shown in FIG. 2. The backing sheet 26 contains marketing information 10. And FIG. 3 shows the cross-sectional view of the foldable prior art sheet of FIG. 1 as viewed along line 3-3 of FIG. 1. As shown, the backing sheet 26 is substantially thin and of approximately similar dimensions as the inner face sheet 22 of the foldable sheet 2. Means for bonding the inner face sheet 22 to the backing sheet 26 is provided by a bonding agent, such as adhesive 24.

SUMMARY OF THE INVENTION

[0006] There are a number of disadvantages in the prior art approach described above. Firstly, the material for the foldable rectangular sheet is flimsy, thereby making the sheet easily susceptible to damage. Secondly, the material is of fairly poor print quality. This low print quality generally distorts the marketing information printed on the outer surface. Thirdly, the predetermined style of labels on the inner surface of the foldable rectangular sheet cannot be seen through the opaque foldable sheet. This prevents the customer from accurately choosing the kind of label style based on his/her preference. Fourthly, the labels on the inner surface cannot be distinguished from the surrounding material (known as the matrix), making it difficult for the customer to peel the labels off the surface. Finally, the labels can be either permanent or removable.

[0007] Thus, what is needed for printable label applications is that the foldable sheet preferably is reasonably strong, has a good print quality, allows a clear view of the style of labels that are present on the inner surface of the foldable sheet, or providing adequate information on the outer surface of the foldable sheet advising the user of the style of label present on the inside surface, and allows a clear and distinguishing border between the labels and the surrounding strip on the inner surface.

[0008] In one embodiment of the present invention, the foldable sheet of printable labels comprises a face paper, a sturdy and high print quality backing sheet, and an adhesive layer between the backing sheet and the face paper. The face paper is die cut to introduce an area for labels. The outer surface of the foldable sheet can include marketing information.

[0009] In another embodiment of the present invention, the foldable sheet of printable labels comprises a face paper, a high print quality backing sheet, and an adhesive layer between the backing sheet and the face paper. In addition, a sturdy insert card is placed inside the foldable sheet. The face paper is die cut to introduce an area for labels. The outer surface of the foldable sheet contains marketing or other information. The package comprising the foldable sheet of printable labels and the insert card is shrink wrapped so as to retain the insert card. The insert card can be disposed of by the customer after opening the shrink wrapped package.

[0010] In a further embodiment of the present invention, the foldable sheet of printable labels comprises a face paper, a sturdy and high print quality backing sheet, an adhesive layer between the backing sheet and the face paper, a cut-out window on the foldable sheet, and a clear liner applied to the cut-out window. The face paper is die cut to introduce an area for labels. The outer surface of the foldable sheet preferably contains marketing information or other indicia.

[0011] In yet another embodiment of the present invention, the foldable sheet of printable labels comprises a face paper, a high print quality backing sheet, an adhesive layer between the backing sheet and the face paper. In addition, a sturdy backing card is places separate from the foldable sheet. The face paper is die cut to introduce an area for labels. The outer surface of the foldable sheet preferably contains marketing information or other indicia. The final package comprising the foldable sheet of printable labels and the backing card is shrink wrapped so as to retain the backing card in place. The backing card can be disposed of by the customer after opening the shrink wrapped package.

[0012] In a still further embodiment of the present invention, the foldable sheet of printable labels comprises a face paper, a sturdy and high print quality backing sheet, an adhesive layer between the backing sheet and the face paper, a cut-out window on the foldable sheet, and a clear liner applied to the cut-out window. The face paper is die cut to introduce an area for labels. The matrix surrounding the labels is patterned differently so as to allow a clear differentiation between the labels and the surrounding matrix for easy label peel-off. The outer surface of the foldable sheet can include marketing, instructional or other information.

[0013] In another embodiment (or a variation of the above embodiments) a high print quality backing sheet is provided. The sheet has a release coating applied on the side that is laminated to the face sheet with an adhesive layer on it.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] More particular description of the invention briefly summarized above may be had by reference to the specific embodiments thereof that are illustrated in the appended drawings. It is to be understood, however, that the appended drawings illustrate only typical embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

[0015] In the drawings:

[0016]FIG. 1 is a top plan view of a prior art sheet depicting the inner face of a foldable sheet containing printable labels;

[0017]FIG. 2 is a top plan view of the prior art sheet of FIG. 1 depicting the outer surface of a foldable sheet containing marketing information;

[0018]FIG. 3 is an enlarged cross-sectional view taken along line 3-3 of FIG. 1;

[0019]FIG. 4 is a view similar to FIG. 3 but illustrating an embodiment of the present invention;

[0020]FIG. 5 is a perspective view of packaging comprising a foldable sheet of the present invention;

[0021]FIG. 6 is a perspective view of the embodiment of FIG. 5 showing an unfolding step;

[0022]FIG. 7 is a perspective view of the embodiment of FIG. 5 showing the sheet unfolded;

[0023]FIG. 8 is a top plan view depicting an embodiment of the present invention comprising a window and a clear liner applied to the foldable sheet;

[0024]FIG. 9 depicts the front and outer surface of the embodiment shown in FIG. 8;

[0025]FIG. 10 is a front view of another embodiment of the present invention comprising a shrink-wrap and a sturdy insert card;

[0026]FIG. 11 is an enlarged cross-sectional view for the embodiment of FIG. 10 taken along line 11-11;

[0027]FIG. 12 depicts an embodiment of the invention showing a sturdy backing card and a shrink-wrap;

[0028]FIG. 13 is an enlarged cross-sectional view of the embodiment of FIG. 12 taken on line 13-13;

[0029]FIG. 14 depicts an embodiment in the present invention where a window emulation is applied or printed to the outer front side of the sheet;

[0030]FIG. 15 is a top plan view of an embodiment in the present invention, where the labels on the inner face are patterned differently from the surrounding face material;

[0031]FIG. 16 depicts a manufacturing process for an embodiment of the present invention; and

[0032]FIG. 17 depicts a manufacturing process for another embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0033] Referring to the drawings, FIG. 5 shows an embodiment of the present invention. The label package 40 comprises a substantially sturdy and thick backing sheet. The first pair of outer surfaces of the backing sheet 42 and 44 contain marketing or other information or indicia 10. The outgoing arrows 45 a, 45 b indicate the unfolding operation for accessing the labels 4.

[0034] Upon unfolding, a second pair of outer surfaces 46, 48 of the backing sheet are exposed as shown in FIG. 6. A glue bead 49 or the like can bond the second pair of outer surfaces 46 and 48 together. Another pair of outgoing arrows 49 a and 49 b indicates another unfolding operation that is performed, in this embodiment, so as to access the printable labels.

[0035] Further unfolding exposes the inner face 50 along with the labels 4, as shown in FIG. 7. The inner face 50 is laminated to the backing sheet by means of a permanent adhesive. Although the labels 4 are shown as being circular, they may be of any shape and of variable sizes. A groove 56 is formed in the foldable sheet for ease in the unfolding operation of FIG. 5.

[0036]FIG. 8 shows another embodiment in the present invention. The foldable sheet 40 has a window 52 that is cut out as shown on the inner face 50. A clear film liner 54, such as a polyester or polypropylene, is affixed to the inner face 50 such as by means of an adhesive. The window 52 provides an easy view for a customer of the style of labels that are enclosed in the packaging.

[0037] As shown in FIG. 4 (which is similar to cross-sectional view along line 3-3 of FIG. 1) for one embodiment in the present invention, the backing sheet 36 is sturdy and made of substantially thicker dimensions than the inner face 32. The material used for the backing sheet 36 is preferably a heavy paper #70 or #100 text, or #50-#60 cardstock. The material used for the inner face 32 is preferably 50# text. The inner face and the backing sheet are laminated together by means of a permanent adhesive, such as a waterbase acrylic emulsion adhesive.

[0038]FIG. 9 shows the label package 40 of FIG. 8, where all the panels are appropriately folded and the label packaging is on display in a store.

[0039]FIG. 10 depicts another embodiment of the present invention. In this embodiment, the backing sheet need not be heavy. Instead, an insert card 58 is placed inside the foldable sheet 40 to make the package substantially sturdy and thick. The insert card 58 can be 60# card or heavier, and a preferred example of the material is a heavy cardstock. This design again prevents the packaging from being easily damaged due to flexing. The package can be shrink-wrapped 56 by means of a material such as plastic to prevent the insert card 58 from separating from the foldable sheet. As an example, the single layer label thickness can be between 5.5 and 8.5 mils, a folded label sheet thickness can be at least twenty mils, and an insert card thickness can be between fifteen and thirty mils. More particularly, the folded label sheet thickness can be between twenty and thirty mils and the insert card thickness can be greater than twenty-one mils.

[0040]FIG. 11 shows the enveloping of the insert card 58 by the foldable sheet 40. The insert card 58 can also be positioned in slits 57 or 59, without substantially changing the nature of the design. A hang tab such as 58 a in FIG. 10 can be used for generally any of the embodiments disclosed herein and particularly those that are shrink wrapped.

[0041] Another embodiment of the present invention is depicted in FIG. 12. In this embodiment, the backing sheet need not be heavy. Instead, a backing card 60 is placed exterior to the foldable sheet 40 to make the package substantially sturdy and thick. The backing card can be a 60# card or heavier and a preferred example of the material is a heavy cardstock. This design again prevents the packaging from being easily damaged due to flexing. The package can be shrink-wrapped 56 by means of a material such as plastic to prevent the backing card 60 from separating from the foldable sheet. FIG. 13 shows the backing card 60 exterior to the foldable sheet 40.

[0042]FIG. 14 depicts another embodiment in the present invention, where an emulated or simulated window 62 is designed on the outer surface 42 of the backing sheet. In this design, the emulated window 62 performs the same function as a real window, without the need for cutting out a window in the manufacturing process. The style of labels in the packaging are projected on this emulated window 62 for example via printing means in the manufacturing process. The window can have a shape other than triangular and a size different than that depicted in the drawings; for example, it can be made larger where the labels themselves are larger.

[0043] The printable labels 4 of the embodiment of FIG. 15 are patterned differently from the surrounding inner face paper 66 (also called the matrix). In the present depiction, the labels are shown clear, whereas the surrounding matrix is patterned or tinted in color. This allows the customer to easily identify the labels 4 from the surrounding matrix 66 thereby resulting in an easy peel-off of the labels. Other differently patterned schemes as would be apparent to those skilled in the art are included in this disclosure.

[0044] Several stages of a manufacturing process are shown in FIG. 16. The raw material (tape) in the form of a roll is constructed of dual face materials that are laminated together by a permanent adhesive. In this manufacturing embodiment, the first three print stations 102 are used to print the outside package graphics on the high gloss side of the material. The web is then turned over by a web turning process 104 and the fourth printing station 106 is used to print on the inside or label side of the product. (Other methods aside from turning the web for printing on both sides of the paper, as would be apparent to those skilled in the art, can be employed.) A first die cutting station 112 cuts the labels using a flexible magnetic die. The second die cutting station 110 die cuts the hat and thumb holes as well as the vertical perforations. The third die cutting station 108 sheets the material into individual sheets. The cut sheet travels along a short sandwich conveyor into folding stations. The first set of folding stations 114 folds the two outside panels (surfaces) in towards the center. Approximately half way through a second single folding station, a glue head 116 lays down a bead of releasable glue in a stitch pattern. The output is sent to a second folding station where it is folded in half and sealed by the glue. The output is sent to an ironing roller 118 and then drops onto a conveyor as a final package.

[0045]FIG. 17 shows an alternative embodiment in the manufacturing process, where a tinting step is added at the beginning of the manufacturing process of FIG. 16. The tinting step 202 applies a combination of four (preferably) colors to the label material. The tinted material then proceeds along the same manufacturing process as described in relation to FIG. 16. Stations 204, 206, 208, 210, 212, 214, 216, 218 and 220 in FIG. 17 correspond to stations 102, 104, 106, 108, 112, 114, 116 and 118 as depicted in FIG. 16 and as discussed above.

[0046] While the specification describes particular embodiments of the present invention, those of ordinary skill can devise variations of the present invention without departing from the inventive concept. For example, while the face sheet has been described herein as being made of paper, it can be made of other materials, such as film or foil. As another example, the processes shown in FIGS. 16 and 17 can be varied such as by adding printing and/or die cutting stations and/or by varying the order of the stations or process steps. Pursuant to a still further example, the matrix at the fold areas only can be removed to make the folding easier. Folding can be accomplished not only by adding perforations but also by other lines of weakness. Additionally, the backing sheet preferably has a release coating applied on the inner surface where it is laminated with the face. Also, the scope of the invention includes any combination of the elements from the different species, embodiments, functions, methods and/or subassemblies disclosed herein, as would be within the skill of the art. 

We claim:
 1. A foldable package of printable labels, comprising: a foldable sheet including a backing sheet and an inner face paper; the inner face paper and the backing sheet being adhered by an adhesive; the inner face paper being die-cut to form printable labels; and a plurality of fold lines on the inner face paper to form a foldable sheet of the printable labels.
 2. The package of claim 1 wherein the backing sheet is made of a substantially sturdy material;
 3. The package of claim 2 wherein the backing sheet is made of heavy paper 70# text.
 4. The package of claim 2 wherein the backing sheet is made from cardstock.
 5. The package of claim 1 wherein the fold lines are made substantially parallel to each other.
 6. The package of claim 1 wherein the fold lines are perforations.
 7. A package of printable labels, comprising: a foldable sheet including a backing sheet and an inner face paper; the inner face paper and the backing sheet being adhered by adhesive; the inner face paper being die-cut to form printable labels; a plurality of fold lines on the inner face paper to form a foldable sheet of the printable labels; an insert card; wherein the insert card is enveloped by the foldable sheet upon folding the foldable sheet along the fold lines; and wrapping material which encloses the foldable sheet and the insert card, so as to preclude the insert card from separating from the foldable sheet prior to unfolding.
 8. The package of claim 7 wherein the insert card is made from cardstock.
 9. The package of claim 7 wherein the fold lines are made substantially parallel to each other.
 10. The package of claim 7 wherein the fold lines are perforations.
 11. The package of claim 7 wherein a single layer (label) thickness is between 5.5 mils and 7.5 mils, a folded label sheet thickness is at least 20 mils, and an insert card thickness is between 15 and 30 mils.
 12. The package of claim 11 wherein the thickness of the folded label sheet is between 20 and 30 mils and the insert card thickness is greater than 21 mils.
 13. A package of printable labels, comprising: a foldable sheet including a backing sheet and an inner face paper; the inner face paper and the backing sheet being adhered by adhesive; the inner face paper being die-cut to form printable labels; a plurality of fold lines on the inner face paper to form a foldable sheet of the printable labels; a sturdy backing card; wherein the backing card is positioned adjacent to the foldable sheet upon folding the foldable sheet along the fold lines; and wrapping material which encloses the foldable sheet and the backing card, so as to preclude the backing card from separating from the foldable sheet prior to unfolding.
 14. The package of claim 13 wherein the backing card is made from cardstock.
 15. The package of claim 13 wherein the fold lines are perforations.
 16. A package of printable labels, comprising: a foldable sheet including a backing sheet and an inner face paper; the inner face paper and the backing sheet being adhered by adhesive; the inner face paper being die-cut to form printable labels; a plurality of fold lines on the inner face paper forming a foldable sheet of the printable labels; a window formed on the foldable sheet; and a substantially transparent liner covering the window and affixed to the face paper.
 17. The package of claim 16 wherein the backing sheet is made of a substantially sturdy material.
 18. The package of claim 16 wherein the plurality of fold lines comprise four fold lines.
 19. The package of claim 16 wherein the thickness of the foldable sheet varies based on the number of folds and the type of label material use.
 20. The package of claim 16 wherein the liner is made of polyester.
 21. The package of claim 16 wherein the liner is made from polypropylene.
 22. The package of claim 16 wherein the fold lines are perforations.
 23. The package of claim 16 wherein the window is a die-cut window.
 24. A package of printable labels, comprising: a foldable sheet comprising a backing sheet and an inner face paper; the inner face paper and the backing sheet being adhered by adhesive; the inner face paper is die-cut to form printable labels, wherein the printable labels and surrounding face paper are of substantially different pattern; a plurality of fold lines on the inner face paper forming a foldable sheet of the printable labels; a window formed on the foldable sheet; and a substantially transparent liner covers the window and affixed to the face paper.
 25. The package of claim 24 wherein the backing sheet is made of a substantially sturdy material.
 26. The package of claim 24 wherein the fold lines are perforations.
 27. The package of claim 24 wherein the window is on a front panel of the foldable sheet.
 28. The package of claim 24 wherein the window is a die-cut window.
 29. A process for manufacturing a package of printable labels, comprising: printing indicia on a first side of a tape; printing indicia on a second side of the tape; die-cutting a series of labels on the second side of the tape; die-cutting perforations on the second side of the tape; sheeting the tape into an individual sheet; and folding the sheet along the perforations.
 30. The process of claim 29 further comprising after the folding, applying a glue bead to seal the package.
 31. The process of claim 29 further comprising after the printing on the first side and before the printing on the second side, flipping the tape to expose the second side of the tape.
 32. The process of claim 29 further comprising applying a tint to the second side of the tape.
 33. The process of claim 32 further comprising inserting a card in the individual sheet.
 34. The process of claim 29 further comprising inserting a card in the individual sheet.
 35. The process of claim 29 further comprising printing multiple colors on the second side of the tape.
 36. The process of claim 29 further comprising after the die cutting the series of labels, removing the matrix on the second side of the tape at fold areas.
 37. A process for manufacturing a package of printable labels, comprising: printing indicia on a first side of a tape; printing on a second side of the tape; die-cutting a series of labels on the second side of the tape; die-cutting perforations on the second side of the tape; forming a window to expose a clear liner; sheeting the tape into an individual sheet; folding the sheet along the perforations; and applying a glue bead to seal the package.
 38. The process of claim 37 wherein the liner is made from polyester.
 39. The process of claim 37 wherein the liner is made from polypropylene.
 40. The process of claim 37 wherein the indicia comprises marketing information.
 41. The process of claim 37 further comprising after the printing indicia and before the printing on the second side, flipping the tape to expose the second side of the tape. 